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Tolerance Stack-Up Analysis

Main Rules
1. Start at the bottom and work up, or start at the left and work to the right.
2. Always take the shortest route.
3. Stay on one part until all tolerances are exhausted.
Step 1
Identify the requirement that is to be analyzed.
Step 2
Identify all dimensions and tolerances that contribute to the gap.
Step 3
Assign each dimension a positive or negative value:

Up is positive

Down is negative

Right is positive

Left is negative

Step 4
Only one set of mating features creates the worst-case gap.
Step 5
The analyst must deduce which geometric tolerance, location or
orientation if either, contributes to the gap.
Step 6
If your assumptions are wrong, your answer is wrong.

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Calculate the Minimum Gap of the assembly below.

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Convert Hole Sizes and Locations to Tolerances

Features with a geometric tolerance are converted to tolerances by adding and
subtracting the resultant and virtual conditions and dividing the sum and difference
by two.

Hole numbers 1 & 2

Resultant Condition

Virtual Condition

6.0
0.4
1.0
7.4

5.0
0.4
4.6

Hole @ LMC
Geometric Tol.
Bonus Tol.
Resultant Condition

Resultultant Condition
Virtual Condition
2)

Hole @ MMC
Geometric Tol.
Virtual Condition

7.4

7.4

+ 4.6

4.6

12.0

2)

2.8

6.0
Dimension with tolerance =

6 1.4

Dimension with tolerance / 2 =

R3 0.7

1.4

Hole numbers 3 & 4

Resultant Condition

Virtual Condition

6.0
0.0
1.0
7.0

5.0
0.0
5.0

Hole @ LMC
Geometric Tol.
Bonus Tol.
Resultant Condition

Resultultant Condition
Virtual Condition
2)

7.0

7.0

+ 5.0

5.0

12.0
6.0

Dimension with tolerance =

6 1

Dimension with tolerance / 2 =

R3 0.5

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Hole @ MMC
Geometric Tol.
Virtual Condition

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2)

2.0
1.0

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Draw the Loop Analysis Diagram

Perhaps the most difficult aspect of tolerance analysis is drawing the appropriate
loop diagram.
START

END

HOLE #1

HOLE #2

MIN
GAP

HOLE #3

HOLE #4

Add Dimensions and Tolerances to the Loop Analysis Diagram

START

END

HOLE #1
30.7

1250
1250

30.5

HOLE #3
30.5

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MIN
GAP

2600
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HOLE #2
30.7
30.5

HOLE #4
30.5

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Add the Vectors and Calculate the Minimum Gap

Add the negative vectors, the arrows pointing to the left, and positive vectors, the
arrows pointing to the right, find the difference between the sums of the positive
and negative vectors, and subtract the sum of the tolerances.
VECTOR DIMENSIONS

125
3

TOLERANCES

3
125
262

+ 266

0.0
0.7
0.5
0.5
0.0
0.5
0.5
0.7
0.0
3.4

of VECTORS

MAX GAP

MIN GAP

3
3
260
3
3

266
262
4

PART
Basic Dim.
Hole #1/2
Pin
Hole #3/2
Basic Dim.
Hole #4/2
Pin
Hole #2/2
Basic Dim.
TOTALS

4.0
3.4
0.6

The steps required to calculate the minimum gap on the above assembly
1. Position the assembly to achieve the minimum gap.
2. Convert the geometric tolerances to equal bilateral plus and minus tolerances.
3. Draw the loop diagram.
4. Algebraically add the vectors.
5. Subtract the sum of all equal bilateral plus and minus tolerances from the algebraic
sum of the vectors.

Technical Training Consultants

(408) 251-5329

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